Prefabricated roof structure

ABSTRACT

A PREFABRICATED ROOF STRUCTURE COMPRISING A PLURALITY OF SECTIONS DERIVED FROM AN INTEGRAL ROOF STRUCTURE BY THE INCORPORATION THEREIN OF MEANS FOR FORMING ACCURATELY REALIGNABLE JOINTS BETWEEN ADJACENT SECTIONS. THE ROOF STRUCTURE PREFERABLY INCLUDES ESSENTIALLY FINISHED FLOOR, WALL AND CEILING SURFACES FOR THE AREA DEFINED BY THE ROOF AND AND ESSENTIALLY FINISHED CEILING FOR THE AREA BENEATH THE PREFABRICATED ROOF STRUCTURE.

1971' W.GREENHALGH PREFABRICATED ROOF STRUCTURE Filed July 21, 1.970

FIG. 2.

IIIIIIIII III INVENTOR William Greenholgh ATTORNEY United States Paten 3,611,659 PREFABRICATED ROOF STRUCTURE William Greenhalgll, R0. Box 521, Oshawa, Ontario, Canada Filed July 21, 1970, Ser. No. 56,878 Int. Cl. 1E04b 7/02 US. Cl. 52-92 Claims ABSTRACT OF THE DISCLOSURE A prefabricated roof structure comprising a plurality of sections derived from an integral roof structure by the incorporation therein of means for forming accurately realignable joints between adjacent sections. The roof structure preferably includes essentially finished floor, wall and ceiling surfaces for the area defined by the roof and an essentially finished ceiling for the area beneath the prefabricated roof structure.

The present invention relates generally to improvements in prefabricated sectional peaked or curvilinear framed roofs and more particularly to prefabricated frame roof structures preferably including room enclosure-defining, floor, wall and ceiling components integral therewith, which roof sections are derived by severing a substantially finished, i.e., exteriorly weather-proofed and interiorly generally completed, integral roof by virtue of means for forming accurately re-alignable joints, followed by shipment of the sections to a building site for efficient, accurate reassembly of the roof sections on previously pro vided substantially conventional load bearing walls.

Numerous prefabricated frame roof structures, both integral and modular, have been devised to facilitate the erection of the roof of a frame or masonry house. Such prior art attempts have been somewhat unsatisfactory in that prefabricated integral roofs, while possibly suitable for relatively small utility type storage buildings, are not practical for dwellings inasmuch as the size and weight of such a prefabricated integral roof makes transportation and erection thereof highly impractical. Therefore, means have been developed to prefabricate roofs by the production of individual modular sections of generally similar juxtaposed mating dimensions. However, the production and subsequent erection of roof structures in this manner does not reliably result in the production of modules which can always be accurately and efiiciently reassembled on previously provided load bearing walls to provide a roof which is structurally and visually equivalent to a roof custom fabricated on site, even when using significant roof sub-assemblies such as prefabricated trusses. In addition, the provision of accurately realignable sections makes it highly practical to provide the roof sections with interior floor, wall and ceiling surfaces for the space defined by the roof as well as a finished ceiling for the space beneath the roof sections.

It is thus a primary object of the present invention to provide an improved method and means for the construction of accurately realignable framed roof structure sections.

Another object of the present invention is to provide improved prefabricated roof sections optionally incorporating dormers, gables, plumbing, electrical wiring, a prefabricated chimney, and the like so as to substantially eliminate on site installation of such components.

Still another object of the present invention is to provide prefabricated accurately realignable framed roof structure sections wherein the space between the rafters and the floor joists is substantially finished and the necessary insulation, electrical wiring, etc., installed, whereby assembly of the sections on site substantailly effects completion of the exterior and interior upper portions of the housing structure.

A further object of the present invention is to provide an improved method and means for severing an integral roof into accurately realignable sections by the provision of appropriately positioned interiorly pre-scored framing members which can be subsequently readily completely severed from the exterior of the integral roof assembly.

Still another object of the present invention is to provide an improved means for severing roof framing members which comprises providing interiorly longitudinally scored, or semi-intersected, members which, after assembly as part of a substantially completed roof assembly, can be readily severed from the exterior of the assembly by means of a longitudinal extending score-line intersecting saw cut.

Still another object of the present invention comprises an improved method of providing a structure with a prefabricated roof, by the steps of constructing an integral framed roof, sub-dividing the roof along previously intersected joint-forming means, transporting the roof sections to the job site, and rejoining the sections on previously load bearing walls.

In carrying out my invention an integral roof assembly is constructed wherein substantially all the components required to make a finished roof are included. In addition, the inside framework required to reinforce the interior and the joint-forming means required to separate the com pleted roof assembly into integral sections is incorporated into accurately realignable roof sections. In the following more detailed discussion of the invention it should be kept in mind that, while the most significant aspect of the present invention is the method and means of separating the roof assembly into accurately realignable sections, the provision of an exteriorly and interiorly substantially completed roof assembly comprise a significant advantage in the building trade art.

Further objects and advantages of the method and means of the present invention will be apparent from the following more detailed description taken in conjunction with the drawings in which:

FIG. 1 is a perspective view of an exemplary embodiment of a framed roof incorporating the novel joint forming means of the present invention, wherein portions are broken away to show certain interior details and two adjacent sections are shown spaced apart subsequent to severing;

FIG. 2 is an enlarged fragmentary vertical cross-sectional view taken substantially along the plane of the line 2-2 of FIG. 1 and showing a partially intersected joint forming member;

FIG. 3 is a fragmentary top plan view of the portion of the roof assembly of FIG. 2, with a portion thereof shown in vertical cross-section, as in FIG. 2, and showing a completely intersected joint forming member; and

FIG. 4 is a vertical cross-sectional view of another embodiment of a joint forming means.

Turning now to the drawings and FIG. 1 in particular, there is illustrated a roof assembly indicated generally at 10 comprising an exemplary embodiment of a framed roof, i.e. a roof assembly having a framework of wooden rafters as at 12, studs as at 14', and the necessary plate members one of which is shown at 16. The roof 10 is for purposes of illustration only shown sheathed on the weather surface, indicated generally at 20, as will best be appreciated from FIG. 2, with building board panels 22, roofing paper 24 and composition roof shingles 26. As will be seen in FIG. 1, the roof assembly 10, in the exemplary embodiment shown, comprises four modular sections wherein the end sections are indicated generally at 28 and 30, and the intermediate sections at 32 and 34. The sections 28, 30, 32 and 34 are shown provided with a dormer 36, intermediate section 32 as shown provided with the upper portion 38 of a plumbing stack vent pipe, and end section 28 is shown provided with a prefabricated metal chimmey flue including a simulated masonry stack as indicated at 40.

The end section 30 is shown provided with exterior sheathing as at 42, which may comprise any suitable building board either in panel or horizontal lapped strip form. The sections 30, 32, and 34 which comprise prefabricated modules are shown positioned and secured in contiguous aligned relation on previously constructed load bearing end and side walls 44 and 46, respectively. End section 28 is shown resting on the load bearing walls and spaced apart from intermediate section 32 prior to being secured contiguous therewith by being moved in the direction of the arrow 48 and secured by suitable fastener means, not shown, to both intermediate section 32 and the load bearing walls.

Turning now to sequentia FIGS. 2 and 3, it will be seen that a significant aspect of the present invention resides in the means, indicated generally at 50, for forming an accurately realignable joint between adjacent roof sections.

With the foregoing in mind, and with particular reference to the embodiment 10 of a roof assembly constructed in accordance with the present invention, the roof assembly 10 is constructed in plant as an integral roof by the use of suitable jigs and whatever mass production techniques are available with the obvious advantage that construction can continue regardless of weather conditions. During construction of an entire integral roof 10, there is incorporated therein joint forming means at the sites where the integral roof is to be subdivided for shipment to a building site for reassembly on previously provided load bearing walls. In this regard, it has been found that to effect accurate realignment of adjacent roof sections it is not normally necessary to provide the joint forming means 50 other than for the rafters. Thus, the joints between adjacent roof sections, i.e. sections 28, 30, 32 and 34, at the floor joists, plates, walls, interior finished ceilings and floor, etc., may comprise conventional nominal construction grade lumber doubled at the site of the transverse joints. It will be understood that when assembling the roof in this manner, the contiguous frame members at the site of a joint are not secured together so that when the sheathing 22 is severed to simultaneously effect separation of the rafter 12, the roof assembly can be separated into its component sections, i.e. sections 28, 30, 32 and 34.

With more specific regard to the joint forming means 50, it will be understood that the rafters 12 are formed from lumber having nominal dimensions approximately 2 /2 times the width required for the loading anticipated, i.e. if a 2 x 10 rafter is required, the joint forming rafters 12 would be formed from approximately 5 x members in the following manner.

The 5 x 10 rafter member 12 would be scored longitudinally at 52 so that after construction of the completed roof assembly 10 the sections 28, 30, 32 and 34 can be derived by sawing, as indicated at 54, through the roofing paper 24, sheathing 22 and previously unsevered portion of the 5 X 10 rafter member 12. As seen best in FIG. 3, the shingling 26 is preferably drawn back when producing the cut 54 so that upon reassembly the staggered shingles can be adhesively secured to fully weatherproof the roof.

As seen best in FIGS. 2 and 3, the cooperating saw cuts 52 and 54 form a non-planar joint between rafter portions 12 and 12", thereby assuring very accurate realignment of adjacent roof sections. Further, as seen best in IFIG. 3, the partially intersecting longitudinally saw cut 52 projects into the rafter 12 sufficiently to insure that the saw cut 54 effects disection of the rafter 12 into portions 12 and 12".

Alternatively, as seen in the embodiment of the joint .4 forming means illustrated in FIG. 4, the non-planar joint may be formed by first sawing a rafter member 12 into portions 112' and 112" prior to assembly of the portions 112 and 112" in contiguous relation to form an integral roof wherein only the exterior sheathing need be severed to provide accurately realignable roof sections. It will further be understood that due to the vagarious nature of construction grade lumber, the fabrication of a joint, as a joint somewhat like the joint 50, by the butting together of two separate distinct members will not normally result in an accurately realignable joint being formed. Thus, the provision of a joint forming means by resawing of a rafter 12 to form rafter portions 112' and 112" is not equivalent to the utilization of two distinct members regardless of their supposedly analogous cross-sectional configuration.

In this regard, and as suggested previously, roof sections encompass not only the roof, per se, but also a finished ceiling formed on the underside of the module as well as, if desired and feasible with the style of roof in question, substantially finished room space within the roof section. Thus, while it will be appreciated that in the case of a shed type roof it is generally not possible to provide a room, when a peaked, mansard, or curvilinear roof type is used, for example, the interior space may be substantially finished.

With the foregoing in mind, in the event that a roof with a slight pitch, i.e. almost fiat pitch, is constructed, the ceiling joists also comprise the rafters. They would be cut diagonally from a 12 inch x 2 inch timber, except at a joint forming means where they would be cut from a 12 inch x 5 inch timber and each piece intersected or disected as described previously. When providing a roof with more than a slight pitch, but where rooms are not to be provided in the roof section, the integral roof would have joists as well as rafters, such as shown in FIG. 1.

As seen in FIG. 1, when providing a finished interior space in the pitched roof 10, and where the roof sections 28, 30, 32 and 34 do not include depending vertical wall sections providing a full top story, knee walls, as at 60, would be provided. Although not shown, it will be understood that necessary permanent diagonal bracing, as required, is provided within the roof sections. In addition, if required prior to severing of an integral completed roof 10, a plurality of temporary diagonal braces may be provided to ensure that when the sections are formed by severing of the integral roof that the sections will maintain their dimensional integrity.

Where it becomes necessary to splice joists because of the dimension of the roof, such splices are made where the roof is to be supported by a bearing wall. It will also be understood that longitudinally extending frame members, such as the ridge board, eave facia and sofiit, for example, will be severed along a transverse vertical plane corresponding to the joint formed by the joint forming means 50.

Although not specifically shown, it will be understood that the roof sections 28, 30, 32 and 34 may be secured in their reassembled relationships to one another and the load bearing walls by any conventional fastener means, including adhesives, if desired. In this regard, a preferred means of securing adjacent sections together is by the provision of generally triangular apertured metal plates, or gussets, adjacent the ridge and eaves, through the apertures in which plates are passed are passed bolts to compress the adjacent sections together. In the event that the areas provided with the joining means are not accessible from the interior of the roof, which will generally be the case, small cut-outs are provided in the sheathing overlying the fastener means to permit applying and tightening of a nut on a previously placed bolt.

Turning once again to FIG. 1, as indicated generally at 62, the knee wall 60 is provided with conventional wallboard such as may comprise gypsum, Wood panelling, or the like. As seen generally at 6 4, the roof section 30 is provided with finished flooring secured to the upper side of the transversely extending floor joists comprising a portion of the realignable roof sections 28, 30, 32 and 34. Further, in accordance with the invention, the sections of an integral roof are provided with all required electrical and plumbing utility lines having appropriate joining means necessary for joining of such lines to one another and to the utility lines provided in the lower portion of the conventionally provided structure. In a similar manner, the necessary insulation is placed Within the Walls and as seen in FIG. 1 sectional rain gutters, as indicated at 66, may be secured to the cave facia.

Turning now to an exemplary mode of assembling the integral roof 10, the ceiling material is secured to the innersides of the joists and this base placed on a suitable planner support surface, the finished flooring is then added while at the same time providing for separation of the assembly transversely at points coinciding with the proposed rafter joint forming means. The rafters are then added and rafters 12, scored as at 52, placed as required, or alternatively, previously severed rafters comprising sections 112 and 112" are assembled in contiguous relation at positions corresponding to those at which the completed roof is to be severed. Insulation, plumbing, electrical wiring and the like are then installed and the walls and ceiling of the area within the roof finished, again keeping in mind that all such elements of the integral roof are capable of being separated without further severing at the sites of the accurately realignable joint forming means 50 to be provided in appropriately spaced rafters 12. The sheathing 22 and 42 is then added followed by the necessary weather proofing, i.e. roofing paper 24 and shingles 26. Assuming all the necessary components are in place, the roof is then separated into the sections 28, '30, 32 and 34 by laying back of the shingles 26 and making three transverse saw cuts 54 from the exterior of the roof, whereby the sections can be lifted by appropriate means for transportation to a building site for accurate realignment on previously provided load bearing walls.

While an exemplary mode of carrying forth my invention has been shown and described herein, it is to be understood that the exemplary mode may be departed from without departing from the invention as set forth in the appended claims.

I claim:

1. A substantially completed and weatherproofed prefabricated framed roof structure for placement on previously provided load bearing walls which roof structure comprises a plurality of accurately realignable roof sections derived from an integral framed roof provided with means for forming transversely extending joints between said plurality of roof sections, said joint forming means including a joint-forming rafter at each transversely extending joint, said joint-forming rafter consisting of two contiguous elongate members derived from a single elongate member by intersecting longitudinally extending generally vertically disposed saw cuts providing a nonplanar rafter joint.

2. The prefabricated and weatherproofed framed roof structure of claim 1 including substantially completed interiorly disposed surfaces providing at least one substantially completed room Within said framed roof structure.

3. The prefabricated and weatherproofed framed roof structure of claim 1 including a dormer extending across at least one of said roof sections.

4. In a prefabricated substantially completed and weatherproofed framed roof structure for placement on previously provided load bearing walls, the improvement comprising the provision of means for forming rafter joints therein whereby said prefabricated roof can be separated into a plurality of transportable accurately realignable roof sections, said joint-forming means including a joint forming rafter at the site of each transversely extending joint, said joint forming rafter consisting of a single elongate member having a substantially rectangular cross-sectional configuration which is provided with a first saw cut partially severing the rafter member longitudinally on the interiorly and downwardly disposed side of the rafter member on a plane non-parallel to the opposed vertical sides of the rafter member whereby said roof can be severed into said plurality of transportable accurately realignable roof sections by a second longitudinally extending saw cut: intersecting said first saw cut providing a non-planar rafter joint.

5. In a substantially completed and weatherproofed prefabricated roof structure for placement on previously provided load bearing walls, the improvement comprising the provision of means for forming transversely extending rafter joints therein whereby said prefabricated roof can be separated into a plurality of transportable accurately realignable roof sections, said joint forming means including a joint forming rafter at each transversely extending joint, said joint forming rafter consisting of two contiguous elongate members derived from a single elongate member by intersecting longitudinally extending generally vertically disposed intersecting saw cuts providing a non-planar rafter joint.

References Cited UNITED STATES PATENTS PATRICK D. LAWSON, Primary Examiner 

